Novel Light Flame-Retardant Heat-Insulated Warm-Retention Protective Fabric and Preparation Method Thereof

ABSTRACT

The present application discloses a novel light flame-retardant heat-insulated warm-retention protective fabric and a preparation method thereof. The preparation method comprises the steps of making soluble fibers and wrapping fibers into core spun yarns by ring spun core-spun spinning method, and weaving the made core spun yarns into a grey fabric by a loom; and then dissolving the soluble fibers in the grey fabric, and finally making the grey fabric into the novel light flame-retardant heat-insulated warm-retention protective fabric upon dyeing and finishing procedures. The protective fabric is a hollow yarn fabric and includes conventional woven goods and knit goods, still air will be generated among the yarns. With respect to the protective fabric with flowing air in the prior art, the protective fabric of the present invention has the advantages of better heat insulation and warm retention, lighter weight and stronger comfort.

BACKGROUND OF THE INVENTION

The invention relates to the technical field of protective fabrics, in particular to a novel light flame-retardant heat-insulated warm-retention protective fabric and a preparation method thereof

Substances against flame, heat, static and chemical acid and alkaline have been extensively required for individual protection of workers working at high-temperature, inflammable and explosive places, such as firefighting, petrochemical engineering, flammable chemicals, power, racing, aerospace and military. Among these, different flame-retardant materials are applied to diversified application fields according to varying flame-retardant requirements. In addition to the flame-retardant requirements, there are requirements of heat insulation and heat stability for flame-retardant materials, because requirements for thermal radiation is always accompanied by requirements for flame-retardance.

The flame retardance, heat insulation and heat stability are the essential conditions for the apparel fabric. In terms of flame-retardant function, the flame retardant requirements can be realized by using flame-retardant fibers or flame-retardant treatment, typical flame-retardant fibers include aramid fibers 1313, flame-retardant viscose, flame-retardant polyester fibers and Modacrylic, while the flame retardance of a cotton fabric is generally realized by flame-retardant treatment. In terms of heat stability, it reflects the dimensional stability and material morphology of the fabric at different temperatures and different time, and heat stability at high temperature can be realized by adding fibers such as LEVLAR and the like. In terms of heat insulation and warm retention, which can be realized by increasing the gram weight of the fabric or increasing the layer number of a composite fabric, whereby the originally heavy clothing will get heavier and more complicate.

It should be further explained that the structure of the flame-retardant heat-insulated protective fabric commonly applied around the world is generally divided into four layers, including: 1. an outer layer: 3A yarn made of 3A fabric, 93% of aramid fibers 1313, 5% of aramid fibers 1414 and 2% of antistatic fibers, the 3A woven fabric woven by the 3A yarns has good heat stability, flame resistance and antistatic performance, gram weight of 180-250 g, but poor heat insulation and warm retention; 2. a second layer: 70-100 g/m2 of needled non-woven layer made of aramid fibers 1313 to strengthen heat insulation and warm retention; 3. a third layer: a flame-retardant non-woven fabric made of water and oil repellent PTFE fibers to achieve the purpose of water and oil repellence; 4. a fourth layer: an inner layer, a woven fabric made by blending the aramid fibers 1313 and the flame-retardant viscose, which is a comfortable layer, with the gram weight of 100-150 g/m2 of the woven fabric. With respect to the fabric of the flame-retardant heat-insulated protective fabric, the above four layers act to provide flame retardance, static resistance, heat stability, heat insulation, warm retention, water and oil repellence, and skin comfort, respectively.

However, the flame-retardant heat-insulated protective fabric above has the defects of being too heavy and tedious during actual use, which makes the users feel extremely unnatural and strong weight oppressive feeling; therefore, countries in the world are looking for light fabrics which can ensure warm retention and flame-retardance to meet market demands. To this end, scientific and technical workers from different countries have been made extensive research on the flame-retardant heat-insulated fabrics to meet the demands, for example, a Chinese patent for invention (patent No. ZL201320683185.1) discloses a double layer fabric interlaced by aramid fibers 1313 and aramid fibers 1414, which using the different heat shrinkable properties of aramid fibers 1313 and aramid fibers 1414 at high temperature, at which aramid fiber 1313 shrinks but aramid fiber 1414 doesn't shrink, thus an air layer among yarns is generated to provide the effects of heat insulation and warm retention; in addition, there is a fabric of which the interior layer of the fourth layer is changed into a raised structure in the prior art, so that comfort can be ensured, and more air layers can be provided to realize heat insulation and warm retention. It can be seen from the technical improvement above that the design essentials of the composite fabric above is to realize the effect of improving heat insulation and warm retention by increasing air ingredient via increasing air or void fraction among the yarns because the heat conductivity coefficient of air is minimum.

However, the air among the yarns of the composite fabric is flowing, although it can play a certain function of heat insulation and warm retention, the flowing air also has heat conductivity. In addition, although the void fraction of the composite fabric above is increased, the gram weight of the fabric is also increased, i.e. the effects of heat insulation and warm retention is only limitedly increased, and the gram weight of single fabric is increased.

BRIEF SUMMARY OF THE INVENTION

The objective of the present invention is to provide a method for preparing a novel light flame-retardant heat-insulated warm-retention protective fabric in view of the defects of the prior art. Yarns of the protective fabric made by the method for preparing the novel light flame-retardant heat-insulated warm-retention protective fabric will generate still air, with respect to the protective fabric with flowing air in the prior art, the protective fabric of the present invention has advantages of better warm retention and heat insulation, and lighter weight and stronger comfort.

Another objective of the present invention is to provide a novel light flame-retardant heat-insulated warm-retention protective fabric, with respect to the protective fabric with flowing air in the prior art, the protective fabric of the present invention has advantages of better warm retention and heat insulation, and lighter weight and stronger comfort.

To achieve the above objectives, the present invention is realized by the following technical solutions.

The present invention provides a method for preparing a novel light flame-retardant heat-insulated warm-retention protective fabric, comprising the following processing steps:

1 a. making soluble fibers and wrapping fibers into core spun yarns by one of the following spinning methods: ring spun core-spun spinning method, Siro-spun core-spun spinning method, compact spun core-spun spinning method, air-jet spun core-spun spinning method or friction spun core-spun spinning method, the soluble fibers are used as interior fiber structure of the wrapping fibers, include soluble filament yarns or soluble staple fiber yarns and are soluble PVA fibers or soluble polyester fibers, the wrapping fibers are flame-retardant fibers or cotton fibers, and the flame-retardant fibers include aramid fiber, flame-retardant viscose, flame-retardant polyester or Modacrylic;

1 b. weaving the core spun yarns made in step 1a into a grey fabric by a loom;

1 c. dissolving the soluble fibers in the grey fabric, wherein the grey fabric can be placed into hot water to dissolve the soluble PVA fibers therein for the core spun yarns made by water soluble PVA fibers; the grey fabric can be placed into an alkaline solution to dissolve the soluble polyester fibers for the core spun yarn made by the soluble polyester fibers;

1 d. making the dissolved grey fabric into the novel light flame-retardant heat-insulated warm-retention protective fabric upon dyeing and finishing procedures.

Another method for preparing a novel light flame-retardant heat-insulated warm-retention protective fabric is provided, comprising the following processing steps:

2a. making soluble fibers and wrapped fiber into core spun yarns by one of the following spinning methods: ring spun core-spun spinning method, Siro-spun core-spun spinning method, compact spun core-spun spinning method, air-jet spun core-spun spinning method or friction spun core-spun spinning method, the soluble fibers are interior fiber structure of the wrapping fibers, the soluble fibers include soluble filament yarns or soluble staple fiber yarns, and are soluble PVA fibers or soluble polyester fibers, the wrapping fibers are flame-retardant fibers or cotton fibers, and the flame-retardant fibers include aramid fiber, flame-retardant viscose, flame-retardant polyester or Modacrylic;

2b. placing the made core spun yarns into hot water or an alkaline solution to dissolve the soluble fibers so as to prepare hollow yarns:

Wherein, weaving the core spun yarns using colored fibers as wrapping fibers into the grey fabric by a loom; dissolving the soluble fibers in the grey fabric, wherein for core spun yarns made by soluble PVA fibers, the grey fabric can be placed into hot water to dissolve the soluble PVA fibers; for the core spun yarns made by soluble polyester fibers, the grey fabric can be placed into an alkaline solution to dissolve the soluble polyester fibers;

the hollow yarns can be woven into a hollow yarn grey fabric by a loom for the wrapping fibers consisting of colored fibers; the hollow yarns can be woven into a hollow yarn grey fabric by a loom after being dyed for the wrapping fibers consisting of non-colored fibers;

2d. making the hollow yarn grey fabric in step 2b into the novel light flame-retardant heat-insulated warm-retention protective fabric upon finishing procedures.

The method for preparing the novel light flame-retardant heat-insulated warm-retention protective fabric above further includes the step of performing flame-retardant treatment after the soluble fibers in the core spun yarns made of cotton fibers are dissolved.

Wherein, as for the core spun fibers using cotton fibers as wrapping fibers, flame-retardant treatment is also required after the soluble fibers in the core spun fibers are dissolved.

Wherein, the content of soluble fibers in the core spun yarns is 0-70%, and the content of wrapping fibers is 30%-100%.

Wherein, the wrapping fibers are colored fibers colored by a stock solution, and include 93% of aramid fibers 1313, 5% of aramid fibers 1414, and 2% of antistatic fibers.

Wherein, the wrapping fibers include 50% of aramid fibers 1313 and 50% of flame-retardant viscose.

Wherein, the wrapping fibers include 93% of aramid fibers 1313, 5% of aramid fibers 1414 and 2% of antistatic fibers.

A novel light flame-retardant heat-insulated warm-retention protective fabric, which is made by the methods described above.

The beneficial effects of the present invention are: a novel light flame-retardant heat-insulated warm-retention protective fabric and a preparation method thereof are provided in the present invention, the method for preparing the novel light flame-retardant heat-insulated warm-retention protective fabric is used for making the novel light flame-retardant heat-insulated warm-retention protective fabric, the substance of the protective fabric is a hollow yarn fabric and includes conventional woven goods and knit goods, still air can be generated among the yarns. Compared with the protective fabric with flowing air in the prior art, the protective fabric of the present invention has advantages of better heat insulation and warm retention, lighter quality and stronger comfort.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be illustrated in combination with the drawings below, however the embodiments in the drawings are not intended to limit the present invention.

FIG. 1 is a flow chart of a piece dyeing preparation method.

FIG. 2 is a flow chart of a yarn-dyed preparation method.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will be illustrated in combination with the specific embodiments below.

Embodiment 1

A method for preparing a novel light flame-retardant heat-insulated warm-retention protective fabric, which is a yarn-dyed preparation method as shown in FIG. 2, including the following processing steps:

1. Soluble fibers and wrapping fibers are made into corn spun yarns, with single yarn 32 s and twisted yarn 32 s/2 by Siro-spun core-spun spinning method, wherein the soluble fibers are used as the interior fiber structure of the wrapping fibers and are 50D soluble polyester fiber filaments, the wrapping fibers are flame-retardant fibers and are colored fibers colored by a stock solution and include 93% of aramid fibers 1313, 5% of aramid fibers 1414 and 2% of antistatic fibers;

2. The core spun yarns are weaved into a grey fabric by a loom, the structure of which is a twill structure, and which is a 1 top/2 bottom fabric;

3. The grey fabric is placed into sodium hydroxide solution with the concentration of 5 g/L, so as to dissolve the soluble polyester filaments at 100° C. for 60 min to obtain a hollow yarn grey fabric;

4. The hollow yarn grey fabric is made into the novel light flame-retardant heat-insulated warm-retention protective fabric upon finishing procedure (softening and shaping), the gram weight of which is 200 g/m2.

Based on the above processing steps and designs, sill air will be generated among the yarns of the protective fabric made by the method for preparing the novel light flame-retardant heat-insulated warm-retention protective fabric in Embodiment 1. With respect to the protective fabric with flowing air in the prior art, the protective fabric of the present invention has advantages of better heat insulation, warm retention, lighter weight and stronger conform.

Embodiment 2

A method for preparing a novel light flame-retardant heat-insulated warm-retention protective fabric, which is the piece dyeing preparation method as shown in FIG. 1, including the following specific processing steps:

1. Soluble fibers and wrapping fibers are made into corn spun yarns, with single yarn 40 s by ring spun core-spun spinning method, wherein the soluble fibers are used as the interior fiber structure of the wrapping fibers, which are 44D soluble PVA filaments, the wrapping fibers are flame-retardant fibers and are natural color non-colored fibers and include 50% of aramid fibers 1313 and 50% of flame-retardant viscose;

2. The core spun yarns are weaved into a grey fabric, which is a plain weave fabric, by a loom;

3. The grey fabric is placed into hot water, so as to dissolve the soluble PVA filament at 100° C. for 60 min to obtain a hollow yarn grey fabric;

4. The dissolved grey fabric is made into the novel light flame-retardant heat-insulated warm-retention protective fabric upon dyeing and finishing procedures (softening and shaping), the gram weight of which is 150 g/m2.

Based on the above processing steps and designs, sill air will be generated among the yarns of the protective fabric made by the method for preparing the novel light flame-retardant heat-insulated warm-retention protective fabric in Embodiment 2. With respect to the protective fabric with flowing air in the prior art, the protective fabric of the present invention has advantages of better heat insulation, warm retention, lighter weight and stronger conform.

Embodiment 3

A method for preparing a novel light flame-retardant heat-insulated warm-retention protective fabric, which is a piece dyeing preparation method as shown in FIG. 1, including the following processing steps:

1. Soluble fibers and wrapping fibers are made into corn spun yarns, with single yarn 32 s and twisted yarn 32 s/2, by compact spun core-spun spinning method, wherein the soluble fibers are used as the interior fiber structure of the wrapping fibers and are 50D soluble polyester fiber filaments, the wrapping fibers are flame-retardant fibers and are natural color non-colored fibers and include 93% of aramid fibers 1313, 5% of aramid fibers 1414 and 2% of antistatic fibers;

2. The core spun yarns are weaved into a grey fabric by a loom, the fabric structure of which is a twill structure and a 1 top/2 bottom fabric;

3. The grey fabric is placed into sodium hydroxide solution with the concentration of 5 g/L, so as to dissolve the soluble polyester filaments at 100° C. for 60 min to obtain a hollow yarn grey fabric;

4. The dissolved grey fabric is made into the novel light flame-retardant heat-insulated warm-retention protective fabric upon dyeing and finishing procedures (softening and shaping), the gram weight of which is 200 g/m2.

Based on the above processing steps and designs, sill air will be generated among the yarns of the protective fabric made by the method for preparing the novel light flame-retardant heat-insulated warm-retention protective fabric in Embodiment 3. With respect to the protective fabric with flowing air in the prior art, the protective fabric of the present invention has advantages of better heat insulation, warm retention, lighter weight and stronger conform.

Embodiment 4

A method for preparing a novel light flame-retardant heat-insulated warm-retention protective fabric, which is a yarn-dyed preparation method as shown in FIG. 2, including the following processing steps:

1. Soluble fibers and wrapping fibers are made into corn spun yarns, with single yarn 32 s and twisted yarn 32 s/2, by compact spun core-spun spinning method, wherein the soluble fibers are used as the interior fiber structure of the wrapping fibers and are 50D soluble polyester fiber filaments, the wrapping fibers are flame-retardant fibers and are colored fibers colored by a stock solution and include 93% of aramid fibers 1313, 5% of aramid fibers 1414 and 2% of antistatic fibers; in addition, the above wrapped fibers are made into warps by ring spinning 32 s/2;

2. The corn spun yarns are placed into sodium hydroxide solution with the concentration of 5 g/L, so as to dissolve the soluble polyester filaments at 100° C. for 60 min to obtain a hollow yarn;

3. The above hollow yarns (used as weft yarn) and warps are woven into the hollow yarn grey fabric by the warp and weft knitting ways via a loom, the structure of the fabric is a twill structure, which is a 1 top/2 bottom fabric;

4. The hollow yarn grey fabric is made into the novel light flame-retardant heat-insulated warm-retention protective fabric upon finishing procedure (softening and shaping), the gram weight of which is 200 g/m2.

Based on the above processing steps and designs, sill air will be generated among the yarns of the protective fabric made by the method for preparing the novel light flame-retardant heat-insulated warm-retention protective fabric in Embodiment 4. With respect to the protective fabric with flowing air in the prior art, the protective fabric of the present invention has advantages of better heat insulation, warm retention, lighter weight and stronger conform.

The above contents are the preferred embodiments of the present invention, modifications can be made to the specific embodiments and the application scope according to the spirit of the present invention by an ordinary person skilled in the art, the contents of the description are not intended to limit the present invention. 

What is claimed is:
 1. A method for making a novel light flame-retardant heat-insulated warm-retention protective fabric, characterized by, comprising the following processing steps: 1 a. making soluble fibers and wrapping fibers into core spun yarns by one of the following spinning methods: ring spun core-spun spinning method, Siro-spun core-spun spinning method, compact spun core-spun spinning method, air-jet spun core-spun spinning method or friction spun core-spun spinning method, the soluble fibers are used as interior fiber structure of the wrapping fibers, include soluble filament yarns or soluble staple fiber yarns and are soluble PVA fibers or soluble polyester fibers, the wrapping fibers are flame-retardant fibers or cotton fibers, and the flame-retardant fibers include aramid fiber, flame-retardant viscose, flame-retardant polyester or Modacrylic; 1 b. weaving the core spun yarns made in step 1a into a grey fabric by a loom; 1 c. dissolving the soluble fibers in the grey fabric, wherein the grey fabric can be placed into hot water to dissolve the soluble PVA fibers therein for the core spun yarns made by water soluble PVA fibers; the grey fabric can be placed into an alkaline solution to dissolve the soluble polyester fibers for the core spun yarn made by the soluble polyester fibers; 1 d. making the dissolved grey fabric into the novel light flame-retardant heat-insulated warm-retention protective fabric upon dyeing and finishing procedures.
 2. A method for preparing a novel light flame-retardant heat-insulated warm-retention protective fabric, characterized by, comprising the following process steps: 2a. making soluble fibers and wrapped fiber into core spun yarns by one of the following spinning methods: ring spun core-spun spinning method, Siro-spun core-spun spinning method, compact spun core-spun spinning method, air-jet spun core-spun spinning method or friction spun core-spun spinning method, the soluble fibers are interior fiber structure of the wrapping fibers, the soluble fibers include soluble filament yarns or soluble staple fiber yarns, and are soluble PVA fibers or soluble polyester fibers, the wrapping fibers are flame-retardant fibers or cotton fibers, and the flame-retardant fibers include aramid fiber, flame-retardant viscose, flame-retardant polyester or Modacrylic; 2b. placing the made core spun yarns into hot water or an alkaline solution to dissolve the soluble fibers so as to prepare hollow yarns; Wherein, weaving the core spun yarns using colored fibers as wrapping fibers into the grey fabric by a loom; dissolving the soluble fibers in the grey fabric, wherein for core spun yarns made by soluble PVA fibers, the grey fabric can be placed into hot water to dissolve the soluble PVA fibers; for the core spun yarns made by soluble polyester fibers, the grey fabric can be placed into an alkaline solution to dissolve the soluble polyester fibers; the hollow yarns can be woven into a hollow yarn grey fabric by a loom for the wrapping fibers consisting of colored fibers; the hollow yarns can be woven into a hollow yarn grey fabric by a loom after being dyed for the wrapping fibers consisting of non-colored fibers; 2d. making the hollow yarn grey fabric in step 2b into the novel light flame-retardant heat-insulated warm-retention protective fabric upon finishing procedure.
 3. The method for preparing the novel light flame-retardant heat-insulated warm-retention protective fabric according to claim 1 or 2, characterized by, further comprising the step of performing flame retardant treatment after the soluble fibers in the core spun yarns made of cotton fibers are dissolved, characterized by, the content of soluble fibers in the core spun yarns is 0-70%, and the content of wrapping fibers is 30%-100%.
 4. The method for preparing the novel light flame-retardant heat-insulated warm-retention protective fabric according to claim 1 or 2, characterized by, the wrapping fibers are colored fibers colored by a stock solution, which include 93% of aramid fibers 1313, 5% of aramid fibers 1414, and 2% of antistatic fibers.
 5. The method for preparing the novel light flame-retardant heat-insulated warm-retention protective fabric according to claim 1 or 2, characterized by, the wrapping fibers include 50% of aramid fibers 1313, and 50% of flame-retardant viscose or the wrapping fibers include 93% of aramid fibers 1313, 5% of aramid fibers 1414 and 2% of antistatic fibers.
 6. A novel light flame-retardant heat-insulated warm-retention protective fabric, characterized by, which is made by the method according to any one of claims 1 to
 5. 